Hello! Hello!.. Welcome to the thread of Headers! I am going to be teaching you today on a HOW TO:
The 05 STOCK Headers+midpipe 600 is heavy.. The 03-04 GSXR1000 headers is light.. I was surprised.. I cannot believe the frickin diffrence from STEEL headers VS. Titanium headers. The weight advantage is a big huge diffrence... You shaved off maybe 15-20 lbs. in weight.. I don't know. Just using my head.. I don't have a weight scale to check.
This mod is 6 on scale of 1-10 easy to hard. It should last you prolly 1-2 hrs. depends on how fast or slow you want to do it. All i did was take my time and everything went smoothly. After everything is done, you will have to modify your fairings, so the exhaust wont touch and melt it.. If you go to the second page on this forum, you will see how i modify my fairings. It don't take much to do and it works real good. Bolt nuts and washers.
Taking old headers off-
You take BOTH fairings off.. Alot of room.. You can use "PB Blaster" or WD-40 to the headers bolts.. let it soak in for like a mins, so you can unscrew those ungodly, nasty, rusted 6mm allen bolts off.. You can skip this step if you want. But, they are hard to get off, if you dont. Take a Long torque bar at it. Then you can unscrew the 10mm at the lower part of the radiator. take the screw out. then you UNscrew the 2 top 10mm bolts on the upper radiator,. Don't take them out.. just loosened it up to where you can move the radiator out towards your front fender. Then grab something you can put in between the radiator and its mounting bracket to keep it coming back down on ya, when your unscrewing the allen bolts off the headers. I grabbed a lil fuse box i found in the garage and used that for this part.. you can see in the pics.. It gave me enough room to unscrew all the headers ALLEN BOLTS out.. I did this very very carefully.. "GO SLOW, TAKE YOUR TIME". dont hit your radiator FINS.. you can bend them easily.. You can always use a small flathead screwdriver to make them straight.. After you take all 8 Allen bolts out, But, before you take your 600 HEADERS OFF.. You need to go where that 12mm bolt is right by your FOOTPEGS and take that off first. before you drop the headers down... THEN "Slowly drop your 600 headers down and SLOWLY pull it out".. Feel How heavy that Son of a bitch IS.. DAMN!
Putting the NEW Headers on..-
I got some extra GASKETS i found in my garage from when i had my 03 600, i was putting full exhaust on.. So i grabbed 4 new GASKETS.. I took 4 of the old ones out.. You can put 4 new ones in or you can keep your old ones you have now, and reuse them.. Then you take the Titanium Headers and "SLOWLY put it up to the gaskets". I put "BLUE" Loctite on the allen bolts When i put them back in.. You can do this, if you want to.. You dont have too. But, in the future they might loosen itself up from all the riding and WOT. Exhaust LEAKS sucks. So, After You put all the bolts back in and hand tighten all of them til the headers seats to the gaskets you put in.. Once all that is done, You proceed to tighten all the allen bolts starting from the middle and work your way out.. i tightened them all down to 16.5 ft. lbs.
when i did it, cause thats what the OWNERS MANUAL says to do.. OR you can handtighten them yourself or whatever.
how it should look when both right and left fairings are off the bike..
OEM 600 headers + midpipe
Your 600 headers + midpipe together vs. 04 GSXR 1000 headers only- no midpipe.
the fuse box i use to space it out.. (You can use whatever you want to space that out)
Old Gaskets which is kept. and (8) headers allen bolts
The 04 GSXR1000 Titanium headers on the bike.. (How it should look after everything is done)
Your Gixxer owners manual, old gaskets on bottom, new gaskets Vesrah on top (if bought)